Apparatus and method for bulking yarn



c. w. ELDRIDGE ETAL 3,194,000

APPARATUS AND METHOD FOR BULKING YARN July 13, 1965v 5 Sheets-Sheet 1 Filed Feb. 2 1960 o wZrL July 13, 1965 c. w. ELDRIDGE ETAL 3, 4, 0

APPARATUS AND METHOD FOR BULKING YARN Filed Feb. 2:. 1960 5 Sheets-Sheet 2 Filed Feb. 2:, 1960 y 1965 c. w. ELDRIDGE ETAL 3,194,000

APPARATUS AND METHOD FOR BULKING YARN 5 Sheets-Sheet 3 6c 5:. r47/ ccomm July 13, 1965 c. W. ELDRIDGE ETAL 3,194,000

APPARATUS AND METHOD FOR BULKING YARN Filed Feb. 2:. 1960 5 Sheets-Sheet 4 July 13, 1965 c. w. ELDRIDGE ETAL 3,194,000

APPARATUS AND METHOD FOR BULKING' YARN 5 Sheets-Sheet 5 Filed Feb. 2 1960 United States Patent C) 3,194,000 APPARATUS AND METHOD FQR BULKING YARN Clare W. Eldridge and Charles W. Long, Rock Hill, S.C., assignors to Celanese Corporation of America, New

York, N.Y., a corporation of Delaware Filed Feb. 2, 1960, Ser. No. 6,129 21 Claims. (Cl. 57- 34) This invention relates to treated synthetic filament yarn and to apparatus for and processes of producing such yarn, particularly yarn containing or made of cellulose acetate or other organic esters of cellulose.

It is an important object of the present invention to provide processes of and apparatus for treating synthetic filament yarn so as to impart thereto novel physical and/ or visual characteristics.

Another object of the present invention is the provision of novel and highly efficacious processes of and apparatus for treating synthetic filament yarn, especially cellulose acetate yarn, so as to impart thereto intermittent varying and/ or randomly distributed physical and/ or visual properties, e.g. bulkiness and color.

A closely related object of the present invention is the provision of novel programming means for controlling the treatment as a whole and for controlling the sequence as well as the spacing and duration of the successive treatment steps or stages.

In this connection it is also an object of the present invention to provide arrangements in which the programming means, which may be of any desired type, serve to actuate a prime mover or motive device which in turn actuates means for initiating and interrupting the various treatment steps or stages.

A further object of the present invention is the provision of programming means as aforesaid which are capable of acting as the control for an intermittent voluminizing operation, for an intermittent chemical treatment, e.g., dyeing or dyeability-changing operation, such as saponification, or for a combination intermittent voluminizing operation and saponification.

Still a further object of the present invention is the provision of yarn-treating apparatus as aforesaid which can be combined with any desired yarn-handling apparatus, such as a downtwister, an uptwister and the like, without in any way affecting the operation of the latter and so as to permit twisting of the treated yarn.

For the purposes of the present invention, that part of the yarn treatment constituted by the voluminizing operation may be carried out by means of a crimper or a bulking jet provided with a chamber into which a highpressure fluid, such as air or steam, is admitted for contact with the yarn running through the chamber. In such a jet, which per Se constitutes no part of the present invention, the bulking tluid floats in a very turbulent, vortical or otherwise non-uniform manner so as to eifect the desired deformation or bulking of the yarn, i.e., of the individual filaments thereof. To effect bulking with such device the yarn must be fed thereto at a speed greater than it is withdrawn therefrom. The degree of bulking may be varied by pas-sing the yarn through an intermittently activated tension gate, clamp or similar device which will create a drag on the yarn so as to reard the passage of the yarn to or from the jet, depending upon the location of the tension device relative to the jet, which location will determine whether bulking or no-bulking takes place when the tension device is active.

Alternatively, bulking can be varied by varying either one of the feed speed or take-up speed relative to the other, or by varying the length of the yarn path between feed and take-up devices as by displacement of a guide over which the yarn passes.

For that part of the yarn treatment constituted by the chemical treatment of spaced sections of the yarn, a. treating device is preferably disposed between the yarn source spool or supply package and the feed rolls which draw the yarn from the said source spool to the down- .twisting ring. Such a treating device may, for example, comprise a rotatable transfer ring or roller the lower half of which is immersed in a bath of dye liquor or an agent for changing the chemical composition of the yarn in conjunction with means for periodically permitting or inhibiting contact between the moving yarn and the transfer :roiler. When the yarn is made of a saponifiable material such as a cellulose ester the treating agent may be an inorganic saponifying agent such as caustic soda,

caustic potash or sodium silicate, or an organic saponifying agent such as a methyl-amine or other lower aliphatic amine. As is well known, the saponified yarn sections of cellulose acetate yarn can be dyed by direct or cotton dyes while the unsaponified yarn sections can be dyed by normal or regular acetate dyes.

When the treatment of the yarn is to include one or more chemical treatments such as dyeing or saponi-fication and a volum-inizing operation, these operations are advantageously coordinated so that the yarn is subjected to both treatments in a single continuous pass from a source to a final position without intermediate re-winding of the yarn. As will be more fully explained hereinafter, such a set-up can be prearranged so that certain specified relationships exist between the bulked and unbulked yarn.

sections on the one hand and the saponified and unsaponified yarn sections on the other hand. The arran-ge ment may be such that only sapon'ified sections are bulked, or that only unsapon-ified sections are bulked, or that parts of adjacent saponified and unsaponified sections are bulked.

More specifically, the present invention contemplates the utilization of a variety of programming means for controlling the entire treatment. Such programming means may be purely mechanical, e.g. a cam, but preferably comprises endless pattern tape made up of tran parent versus opaque or perforate versus imperforate portions which can be sensed optically, electrically, or otherwise. The sensing means is most advantageously arranged to generate electrical signals, for example upon passing of a perforated or transparent portion of the tape, which can be employed to actuate the operationinitiating elements of the bulking and/ or sap'onifying devices.

In accordance with one aspect of the present invention, a valve is used for controlling the actuation of the aforesaid operation-initiating elements of the bulking and/ or saponifying devices and in particular for controlling the actuation of the prime movers, e.g. pneumatic motors, for these elements. The valve may be a quick-acting mechanical valve provided with an operating plunger slidably engaging the suitably contoured periphery of a rotating pattern cam. The cam thus constitutes the pro gramming means for regulating the entire treatment. The

arrangement is such that for the bulking operation the valve causes the yarn tensioning device to be actuated and deactuated at such spaced intervals as are determined by the contours of the cam periphery, while for the saponification the valve causes a yarn-shifter element to bring the yarn into or out of contact with the saponifying agent transfer roller.

Alternatively, the valve may be a solenoid valve with gramming means for regulating the entire treatment.

When the treatment comprises both bulking and saponifying, they can be controlled by the same or separate programming means. 7

In accordance with another aspect of the present invention, the tensioning device or the saponifying device, or both, may be actuated directly by electromagnetic means energized in response to transmission thereto :of the signals generated by the sensing devices. 'T, he valves and associatedprime movers can then bevdispensed with. It

herein. Merely by wayof example, the jet may be an is further contemplated by the present invention that the I V said sig'nalsmay also be employed tocontrol the admis 'sion of bulking fluid into the jet if a continuous how of bulking fluid is not desired. 7

The foregoing and other objects, characteristics "and advantages of the present'invention will be more clearly understood from the'following detailed description thereair jet asjdisclosed in British Patent No. 776,410, orjan .air or steam jet such as those disclosed in US. patent application Serial No. 777,673 filed April 14, 1958 in the name 'of' C. W. Palm, now US. Patent No. 3,022,563, and US. patent application Serial No. 812,718 filed May 12, 1959 in the names of' James O. Smith and Carl R. Delagrange, all assigned to the assignee of the present application. Whatever type of jet is employed, however, the arrangement is suchthat when yarn is overfed into the jet, the fluid supplied to the bulking chamber, due to its turbulent flow out of the chamber, causes the yarn to be'deforme'd and rendered considerably more bulky and, voluminous-than .it was prior to entering the jet.

:Theyarn tensioning or clamping device 21 essentially comprises a pair of flat-faced discs 23' and 24, of which the disc 24 maybe stationarily mounted. A pair of pins 25, 26 project from disc, 24, through alignedapertures in disc 23 to ensure that a yarn threaded betweenthe discs 23,24 and pins 25, 26 will notbe displaced to a location where it can avoid :being acted upon byfldiscs23, 24

' is connectedto a. piston rod 27 slidably extending from.

' one end of acylinder28 of a double-acting pneumatic of when read in conjunction with the accompanying J drawings, in which:

FIG. 1, is a schematic illustration of a downtwister in combination with an intermittent bulking device" constructed in accordance with the present invention; 8

FIG. 2 is a fragmentary schematic illustration, in. perspective, of an intermittent s-aponifying. device'adapted to be operationally combined with the downtwister shown r in FIG. 1; j V e ,FIG. 3 is a schematic illustration of a pattern tape,

constituting the -programming means for the yarn treatment, with a-feeler electrode type of pick-up unitor sensing device; 7

FIG. 4, is a similar schematic illustration of the pattern tape with a photoelectric cell type of pick-up unit or sensing device;. 1 g

FIG. 5' is a schematicillustration of a contoured pattern cam, constituting the programming means for'the yarn'treatment, as it coacts with a treatment-controlling valve; and V 1 I 7 FIGS. 6, 7 and 8 are block diagrams representing possible variations in the programming arrangement and thus in the treatments which can be carried out by the apparatus according to the present invention.

Referring now first to FIG. 1, it will be seen that the downtwister D there illustrated (which isbasic ally a conventional structure and constitutes no part of the present;

invention) comprises a pair of feed rolls 1!) and 11 and a downtwistingring 12. Yarn 13, which is initially wound on a supply package or spool 14, is drawn from the latter through pigtail guides 15 and ltiby the feed rolls.

10 and 11 a'ndis fed by the latter through pigtail guides 17 and 18 to the downtwisting ring 12 by means ofwhich the yarn is wound onto a take-up spool or package 19.

. In combination with the downtwister shown in FIG. 1 there is provided, in accordance with one aspect of. the present invention, a bulking device B for intermittently bulking the yarn 13. This device comprises a jet 2 0 and a yarn tensioning or clamping device 21 both of which are disposed along the path of travel of the yarn 13 between the feed rolls 10-11 and the downtwisting ring 12. The jet 20 essentially comprises a housing in which is defined a chamber (not shown) throughwhichthe yarn 13is adapted to pass. Communicating with the chamber is,

an inlet tube, or conduit 22 through which a gaseous or vaporous bulking fluid under high pressure "may be admitted into the chamber.

-As previously stated, the actual construction of the jet 20 comprises no part of the present invention, and thus it is not deemed necessary toillustrateithe jet specifically respect to the tensioningor clamping disc 23 and is of conventional construction, adapted to operate with air under a pressure of about 10 tov p.s.i., is associated with a solenoid valve 30 which controls the flow of air through the supply line, or conduit 31, into the cylinder 28. The operating coil of the valve 30 is provided with electricalleads or co'nductorsr32 and 33 by means of which valve-actuating. signals generated in a manner presently to bedescr ibed may be transmitted to the coil.

I The operation of the yarnrtreating system so far described will be understood by considering that when the discs 23and 24 are spaced from oneanother, the yarn 13.

is under tension throughout its length between the feed rolls 10-11 and the downtwisting ring 12. The yarnis thus drawn out of the jet 20 as fast as it is being fed thereinto, as a result of which no bulking of the yarnwill take place. At this time, therefore, the yarn is being wound onto the. spool 19 while simultaneously being twisted dueto the action. of the downtwisting ring 12. As soon as the disc23 is moved against the disc. 24, however, to'clamp the yarn 13 .therebetween, feeding of-yarn to the speel 19 is abruptly terminated, the rotation of the spool merely introducing twist into the portion of the "yarn from discs 23-2-4and ring 12. At the same time, of course, the feed rolls l0. and 11, continue to feed yarn '13 into the jet 2t whereby the yarn upstream of discs 23,

'on'the spool 19 again commences, so that further bulking of the yarn within the jet is inhibited. As the yarn is wound onto the spool 19, the twist imparted by the ring 12 serves to stabilize the yarn in its deformed or bulked 'state to' ensurethat itwill not straighten out upon subsequent handling. I

Means are provided in accordance with the present invention for programming the opening and closing of the discs 23 and 24 and thus for releasing'and clamping the yarn 13, respectively. Referring particularly to FIG. 3, itwill be seen that the programming means according to this aspect of the present invention comprises a pattern tape 34 in which are provided a number of perforations or slots 35 separatedby imperforate portions36 and 37. As illustrated, the slots 35' differ from one another in longitudinal dimension or size in a completely random manner, whiletheimperforate portions 36 and 37 also differ from one another in size in a random manner. As

alternatives it is possible, of course, to provide uniformly motor 292. The motor 29, which is a prime mover with Y dimensioned slots spaced randomly, randomly dimensioned slots spaced uniformly, or uniformly dimensioned slots spaced uniformly. The pattern tape 34, only a short portion of which is shown, advantageously is endless and adapted to be moved by any suitable drive and idler roll mechanism (not shown). The arrangement is such that the tape passes between a grounded base elec trode 38 and a feeler electrode or sensing member 39 which is resiliently urged in the direction of the tape and electrode 38. The electrodes 38 and 39 are connected into the power circuit of any desired control circuit, such as an electronic relay 40, two terminals 40 and 40" of which are connected to the solenoid valve via the conductors 32 and 33.

From the foregoing it will be understood that when one of the perforations 35 of the tape 34 is disposed between the electrodes 38 and 39, these will be in electrical contact with one another and will actuate the relay or control circuit in such a manner as to generate a signal adapted to be transmitted to and energize the coil of the solenoid valve 36. The latter is thus shifted into a position for admitting fluid into the cylinder 28 so as to move the piston rod 27 outwardly and to press the disc 23 against the disc 24. As a result, the yarn then being fed into the jet will become slack and will be bulked in the aforedescribed manner. As soon as the pickup or feeler electrode 39 contacts an imperforate section of the tape 34, the solenoid valve 30 will be reversed due to opening the circuit for the relay 40 so as to efifect admission of fluid into the cylinder 28 in a manner tending to retract the piston rod 27 and separate the disc 23 from the disc 24. The take-up of the yarn is then resumed until the feeler electrode 39 again comes into electrical contact with the base electrode 38 through the next perforation 35 in the tape 34.

It is possible, according to the invention, to substitute for the electrode type pick-up unit 3839 a photoelectric type pick-up unit or sensing device. Such a system, illustrated in FIG. 4, comprises a lamp or other light source 41 and a photoelectric cell or similar light-sensing element 42 disposed on opposite sides of the path of movement of the pattern tape 34. The light source 41 and cell 42 are connected in circuit with a relay or control circuit 43. The latter, which may be the same as the relay 40 shown in FIG. 3, has its output terminals 43 and 43" connected with the conductors 32 and 33 leading to the coil of the solenoid valve 30. As will be readily understood, light will be incident on the cell 42 whenever the tape 34 has moved to a suflicient extent to dispose one of the perforations 35 between the cell 42 and the light source 41. When the resultant electrical signal energizes the valve coil, the disc 23 will be pressed against the disc 24 to inhibit further take-up of yarn onto the spool 19 and thus to cause an overfeeding of additional yarn 13 into and through the jet 20, whereby the yarn is bulked by the action of the high pressure bulking fluid admitted into the jet through the inlet conduit 22 thereof. As soon as an imperforate portion of the tape 34, for example that shown at 37 in FIG. 4, reaches the gap between the light source 41 and the cell or sensing element 42, the solenoid valve 30 is reversed so as to effect retraction of the disc 23 from the disc 24. Yarn take-up now again commences and, due to tension in the yarn, no further bulking will take place until another of the perforations 35 in the pattern tape 34 is located between the light source 41 and the cell 42.

One of the principal advantages of a programming ar- Iangement of the type shown in FIGS. 3 and 4 is that the use of a pattern tape allows attainment of great flexibility in the choice of patterns of random yarn treatments. This is due to the fact that it is possible to perforate the tape for extremely long term repeats without taking up an excessively large amount of space for the tape-driving mechanism and the associated sensing device and without complex variable speed mechanisms. For

example, the tape can be endless and housed in a suitable magazine or it may be spirally unwound at constant speed from one spool to another using an inexpensive drive such as is employed for motion picture projectors or tape or wire recorders. Moreover, due to the easy interchangeability and combinability of such tapes, an almost infinite variety of random treatment patterns can be attained.

In lieu of the pattern tape 34 shown in FIGS. 3 and 4 and the associated sensing means, it is possible in accordance wtih the present invention to employ a mechanical programming means, as shown diagrammatically in FIG. 5. Such a mechanical programming means may be constituted, for example, by a cam 44 adapted to be rotated about an axis 45 by any suitable constant or variable speed drive means (not shown). The outer periphery of the cam 44 is contoured in a predetermined manner to provide a plurality of irregularly sized and/ or irregularly spaced elevations or lobes 46 and depressions 47 the function of which will become clear presently.

In view of the mechanical nature of the pattern cam 44, the solenoid valve 30 is replaced in this embodiment of the invention by a quick-acting mechanical valve 48 which is provided with an air supply line 49 and a pair of flow lines 50 and 51 adapted to be connected to the cylinder 28. The valve 48 is provided with a reciprocally displaceable valve element (not shown) controlling the communication between the supply line 49 and the flow lines 50 and 51. Attached to this valve element is a plunger 52 which extends from the housing of the valve 48 and carries a roller or like contact element 53 slidably engaging the outer periphery of the pattern cam 44. The valve element in the valve 48 is preferably spring-biased in such a direction (upwardly as shown in FIG. 5) to maintain the contact element 53 in engagement with the peripheral surface of the pattern cam 44 and to normally urge the valve element into such a position that fluid is so directed into the cylinder 28 as to separate thedisc 23 from the disc 24. This condition corresponds, for example, to engagement of the contact element 53 on the plunger 52 with one of the depressions 47 on the pattern cam periphery.

From the foregoing it will be understood that as soon as the cam 44 is rotated sufiiciently to bring one of the lobes or elevations 46 into engagement with the contact element 53, the valve plunger 52 and therewith the valve element will be depressed and shifted to the position in which iluid admitted, into the cylinder 28 causes the piston rod 27 to be advanced and the disc 23 to be pressed against the disc 24. The yarn will then be clamped against movement past the tensioning device 21, whereupon the portion of the yarn 13 in the jet 20 at that time will be bulked as previously described. As soon as the cam rotates further to bring the next depression 47 into engagement with the contact element 53, the valve 43 will be operated to cause retraction of the piston rod 27 and separation of the disc 23 from the disc 24, thereby permitting take-up of the yarn onto the spool 19 and inhibiting further bulking until the following elevation 46 of the cam reaches the contact element 53.

The intermittent bulking arrangement according to the present invention as heretofore described is, of course, susceptible to a number of variations. For example, it is possible to employ in lieu of the pneumatic motor-actuated clamping discs 23 and 24 a pair of discs which can be drawn against one another electromagnetically. Thus, the stationary disc 24 may be associated with a relatively powerful electromagnet while the movable disc 23 is made of a highly magnetic material. In this case, neither the pneumatic motor 29 nor the solenoid valve 30 or mechanical valve 48 would be needed. Instead, the electric pick-up unit 38-39 or the photoelectric pick-up unit 41-42 would be connected directly :or through the intermediary of suitable control circuitry to the coil of the electromagnet associated with the disc 24. The latter would then be actuated by signals generated by the pick-up unit, to draw the disc 23 against thedisc 24 and thus to clamp the yarn therebetween, whenever one of the perforations 35 of the pattern tape 34 is located within the range of the associated pick-up unit, i.e., either between the feeler electrode 39 andthe base electrode 38 or between the photosensitive cell 42 and the light'source 41. In an alternate electromagnetically actuated device, the disc 23 is carried by an armature whichis displaced electromagnetically. Such electromagnetic devices are especially useful since they are cheap, compact, fast acting and easy to install and main tain. a a

It is further. possible in accordance with the present invention to provide bulking fluid for the jet, 20 only intermittently and insubstantial synchronism with the actuation of theclamping device 21. To this end it would merely be necessary to connect the output of the pattern sens- 'ing device to the valve (not shown) which controls the flow of air through the line 22 into the jet. Merely by way of example, if this valve is a mechanical valve of the quick-acting type, it may he -actuated by a cam identical into the cylinder 68 for the, purpose of reciprocating the piston (not shown) therein and therewith the piston rod 67 is controlled by a solenoid valve 70 provided with electrical conductors'72and 73 which are adapted to be connected to the output of either the electronic relay 4%) shown inFIG. 3 or the control circuit 43 shown in FIG. 4. In allres pects except forthearticulation joint 66,

the pick-up, device 38-39 or the pick-up device 41-42, a

signal will be generated "and transmitted via either the circuit 40 or'the circuit'43 and the conductors 72 and 73 to the solenoid valve 70 for actuating thesame so as to cause the piston rod 67 to be protracted from the cylinder 63. The upper end 65 of the rocker arm 65 will thus be moved to the left as shown in FIG. 2, causing the shaft '61 to be rocked in a counterclockwise direction. In this manner, the yarn 'lifter' element 63 is moved from its raised, solid-line posiiton to its lowered, broken-line position. This permits the yarn-13, which previously was constrained to move across the trough 54 along an angular, upwardly deflected jpath; determined by the raised actuation of the tensioning or clamping device 21. 'If desired, a time delay arrangement, to which reference will be had more fully hereinafter, can be provided to permit flow of fluid into the jet either before or after the tensioning device 21 is actuated. "I

By supplying the bulking fluid only intermittently, its consumption is held to a minimum with attendant economic advantage since no fluid is wastefully supplied when the jet is incapable of bulking due to tension onthe yarn.

Moreover, by supplying the bulking fluid in synchronisrn with the actuation of the clamping device 21 closer control of the bulked lengths can be had, eQg. the bulked,

lengths can be made short and abrupt and the unbulked 7 lengths will be substantially free of loops,

Turning now to FIG. 2 of the drawings, it will be seen that the intermittent saponifying device S according to the present invention comprises a trough or similar receptacle 54- in which is containeda quantity of any suitable saponifying agent 55.1 As hereinbefore stated, the saponifying agent may be inorganic,e.g.' caustic soda, caustic potash or sodium silicate, or organic, e.g. a methyl-amineor' other lower aliphatic amine. Mounted on a pair of ledges 56 at opposite sides of the trough 54 are two pigtail guides 57 and 58 through which the yarn 13 is drawn by the feed rolls 10 and 11 of the downtwister D. Extending along and above the trough 54 is a rotatable shaft 59 to which is fixed, as by a setscrew or a key and groove arrangement (not shown), a ring or, annular transfer roller60. The arrangement is such that the lowermost portion of the roller 60 is immersed in the saponifying agent '55, as shown I at and that the uppermost peripheral portion of the roller is located in the path of undeflected movement of, the yarn 13 across the trough 54 and between the pigtail guides 57 and 58.

I ournaled adjacent the trough 54 for angular reciprocal movernent about an axis substantially parallel to the axis of the shaft 59 is a shaft 61 to which is fixed a transversely extending arm 62. The arm 62'extends from the shaft 61 to a point located adjacent one side of the transfer roller 60 andis provided with yarn lifter element 63 end 66 of a piston rod 67 extending slid'ably frorn a cylinder 68 of a pneumatic, motor 69. The admission of'fluid The rocker arm is bifurcated at its nature of the programming means. example, with a pattern tape 34 as illustrated, the color position of the lifter element 63, to travel along a substantially linear undeflected path, as shown at 13'. When moving along this path, the yarn contactsthe transfer roller 60 at its uppermost periphery and the latter thus transfers a quantity; of the saponifying agent 55 to the yarn 13. As soon as an imperforate portion of the pattern tape interrupts the signal generated by the pick-up device, the ,piston rod 67 is retracted into the cylinder 68 and the shaft61 rocked in a clockwise direction to return-the lifterelement 63 to its'raised position. The yarn 13 is now againout of contactwiththe'transfer roller 60 and Will, therefore, not be saponified.

i As' in the case'of the solenoid valve30 associated with the pneumatic motor 29, of course, the solenoid valve 70 'may be eliminated and replaced by a quick-acting mehereinbefore in connection withthe yarn clamping discs 23and '24;

a The present invention further contemplates the pro ivision of an apparatus for subjecting the yarn 13 to a combination treatment, i.e., an intermittent bulking operation and anintermittent saponification. To this end, the

'saponifyingdeviceshown in'FIG. 2 can be readily incorporatedlin the downtwister shown in FIG. 1, it being evident from FIG. 2" that the saponifying'device S would suitably be located between the pigtail guides 15 and 16 shown in FIG. 1.' In this manner, there is produced a voluminous yarn which is intermittently bulked and which has an aflinity at alternating sections for normal acetate dyes and for direct or cottonrdyes. Accordingly, either the yarn in its undyed state or a fabric formed from the undyed yarn can then be passed through separate baths of the two types of dyes mentioned above;- The ultimate yarn or fabric will thus have a dual color effect, with the distribution of the like colored sections depending on the Merely byway of distribution will be completely random and irregular. As before, however, a certain irregularity could be attained by a tapehaving constant-length slots irregularly spaced or random length slots regularly spaced.

a From the foregoing it will be clear that it is possible Ito attain in accordancewith the present invention a considerable variety of relationships between the bulked and saponified sections of the yarn. Thus, arrangements can be devised in which only the saponified sections are bulked, or in which only the unsaponified sections are bulked, or in which a region of bulking in the yarn extends into both a saponified section and an unsaponified section, or in which these relationships may shift and actually go from any one of the above categories into the others without any set rule. Three representative arrangeemnts for accomplishing such results are shown in FIGS. 6, 7 and 8 of the drawings.

Referring first to FIG. 6, it will be seen that there is here illustrated in the form of a block diagram a combined intermittent saponification and bulking system and process in which the yarn taken from a supply package or spool 14 is passed through a saponifying device S as shown in FIG. 2 and is then fed by feed rolls 1041 to an intermittent bulking device B consisting of a jet intermittently supplied with air and yarn clamping device 21 as shown in FIG. 1. Thereafter, the yarn is wound onto a suitable take-up spool 19. A pattern tape 34 constitutes the programming means. The perforated and imperforate portions of the pattern tape 34 are sensed by the spaced sensing elements of a pick-up unit P (either the electrodes 38 and 39 or the light source 41 and photosensitive cell 42). The pick-up unit generates a signal in response to the passing of a tape perforation between the sensing elements of the pick-up unit, which signal is sent simultaneously to the intermittent saponifying device S and to the intermittent bulking device B. In the illustrated arrangement, therefore, the signal would be delivered to the solenoid valves and 70 and to the solenoid valve (not shown) which controls the line 22 leading into the jet 20.

With this arrangement, the treatment of the yarn is such that the saponified sections of the yarn do not necessarily coincide with the bulked sections of the yarn, although such coincidence may occur. This is due to the fact that, although both the bulking and saponifying operations take place at exactly the same instant, each bulked section always lead-s the saponified section which is formed at the same time. Thus, any given saponified section would not necessarily be bulked unless the distance between the saponifying device S and the bulking device B were an exact multiple of the length of the same saponified section. This, however, is an eventuality which could only occur very rarely in view of the random dimensioning and spacing of the perforations in the pattern tape 34. The resultant yarn not only has irregularly dimensioned and spaced bulked sections as well as irregularly dimensioned and spaced saponified sections, but is also characterized by a completely random arrangement and distribution of the bulked sections relative to the saponified and unsaponitied sections. A change in the dimensions and/ or spacing of the slots or perforations 35 will, of course, change these relationships correspondingly.

The same result can be attained by employing two pattern tapes and two pick-up units without any particular or predetermined timing relationship between the pattern tapes and without any predetermined relationship between the dimensions and spacing of the perforations in the respective tapes.

Referring now to FIG. 7, the yarn treating system there illustrated in the form of a block diagram is substantially identical with that shown in FIG. 6 but differs therefrom in that two pick-up units P and P" are employed to sense the perforations in the pattern tape 34. The first pick-up unit P delivers its signal only to the saponifying device S, while the second pick-up unit P" delivers its signal only to the bulking device B. With respect to this latter signal, it is to be understood that the same may be delivered, as illustrated, to the two solenoid valves which control the flow of fluid to the jet 20 and to the yarn clamping device 21, but if desired the signal may be delivered only to the yarn clamping or tensioning device, especially if a continuous fiow of bulking fluid to the jet is maintained. An arrangement of the type just described, i.e., where two pick-up units are arranged in tandem for sensing the same pattern tape, renders possible a yarn treatment in which each saponified section is bulked while each unsaponified section is unbulked, or in which each unsaponified section is bulked while each saponified section is unbulked. To accomplish this result, it is necessary to establish a predetermined relationship between the spacing of the pick-up units from one another and the spacing of the saponifying device S from the bulking device B. This relationship can be expressed by the formula wherein l distance between pick-up units,

l =yarn distance from saponification point to bulking point,

V =pattern tape speed, and

V =yarn speed.

Substantially the same effect can be attained through the use of two pick-up units P and P" each of which is arranged to sense a respective one of a pair of pattern tapes 34 and 34" (see FIG. 8) provided with substantially equivalent patterns of perforations. As an alternative to the foregoing, the two pick-up units could be employed in conjunction with a single pattern tape in which are provided two channels of perforations, with each pick-up unit sensing the perforations in one of the channels. The treatment carried out by a system of this type will be the same as that carried out by the system of FIG. 7 as long as the distance between the pick-up units satisfies the relationship defined by the formula set forth hereinabove.

It will be understood that the ultimate characteristics of the yarn wound onto the take-up spool 19 depends on a number of factors over and above those included in the above formula. Thus, the initial denier of the parent or source yarn, the number of filaments making up the yarn, the type of jet employed and the operating conditions thereof, the initial and final twists imparted to the yarn, and the distance between the jet and the yarn tensioning or clamping device, as well as the types of properties of the saponifying agent and dyes employed, all contribute to the ultimate appearance of the product yarn. For example, the pressure of the bulking fluid admitted into the jet 20 may vary from about 20 p.s.i.g. or less to about p.s.i.g. or more, but for optimum bulk fullness the pressure should be about 40 to 60 psig The distance between the jet 2t) and the clamping device 21 may be as little as inch and as great as 6 inches or more, depending on the lengths of bulked sections desired. Bulked length, of course, varies not only as a direct function of this distance, but also as a direct function of the feed roll speed, i.e., the quantity V for any given time signal generated by the pick-up unit controlling the bulking device. The state of twist of the yarn has been found to have no appreciable effect on the bulked length as such, but it does effect the appearance of the product yarn in that with an increase in twist the ends of the bulked sections become more abrupt.

In place of, as well as possibly in addition to, the saponification the running yarn may intermittently be contacted with one or more dye liquors to impart varied color effects directly. If volatile solvents are employed they will for the most part be evaporated during ballooning immediately preceding take-up on the bobbin by the downtwister. If effected prior to air jet bulking obviously the pressurized air will aid in drying the yarn. In the event, however, that a more positive cleaning is desired the fully wound bobbin may be immersed in wash liquors, followed by drying.

The features of the present invention will be more clearor cotton dye imparts to the fabric a novel-and A 300 denier source yarn made up of 85 cellulose acetate filaments with 0.27 turn per inch, is unwound from the supply package 14 and fed by the feed rolls 10 and 11 through an air jet 20 and past the clamping device 21 to thetake-upspool19. The feed roll peripheral speed is 73 yards perminute, and the air pressure in the bulking jet is 50. p.'s.i.g. The distancebetween the jet and the clamping device is inch. A. signal from the pattern pick-11p unit is employed to actuate both the clamping or tensioning device and, the air feed to the jet at the same instant. The proportion of time during which discs Z3 and 24 are in contact to permit bulking is set to provide a production rate about 22 yards per minute. conditions the bulked portions vary in length between about 1.5 and 9 inches. 7 7

Example II Under these.

The operation of Example I is repeated, with a yarn.

twist of turns per inch and a feed roll speed, of 33 yards per minute. Air pressure in the jetis set at 60' p.s.i.g. The distance between the jet and the tensioning device is 6 inches. Under these conditions bulked is between about Sand 12 inches.

Example 111 A yarn similar to that employed as the parent yarn'in V Example II'is first passed over a saponifying'device such as that shown in-FIG. 2, The saponifying'agentin the trough is a solution of' sodium hydroxide in water. The yarn lifter isintermittently actuated by the same signal as the tensioning device-so asto form alternatingsaponified and unsaponified' sections in the yarn; Thereafter the yarn is subjected to the treatment conditions set forth in Example II; The resultant product yarn when woven into fabric and dyed with an acetate dye andwith a direct highly pleasing dual color etfect. a

7 Example IV The process of Example III is repeatedwith the following changes: In place of sodium hydroxide the trough contains a solution made up, by weight, of 75 parts of ethyl alcohol, parts of water and.1.5 parts of Xylene Milling Blue GL. The bulking. treatment is omitted.

or slub length, j

Theresulting yarn is dry on the bobbin and is intermittently colored blue. I I

Yarns made-in accordance withthe teachings of the present invention can be employed in the manufacture of a variety of consumerproducts in which specialty effects are desired. For example, such yarns can beemployed in the manufacture of fabrics for mens suits and coats,

upholstery and furinture coverings, automobile seat covers, carpeting, blankets,idrapes and the like. a a Itiis tobe understood that the foregoing detailed description isgiven merely' by way ofillustration and that 7 many variations: may be made therein without departing from the spirit of our invention.

Having described our invention what we desire to secure by Letters Patent is: V

physical structure of said programming means at said detectionstation, and controlling all of said treatments through the intermediary of'said sensed physical structure variations of said, programming means to efiect "alternating andsuccessive starts and-interruptions of-each of said 4. The process of claim'Z, wherein only thosesections of: said yarn not subjected to said chemical-applying operation are subjected to said voluminizing operation.

5. The-process of claim 2, wherein'spaced sections of said yarn each made up partly of a section subjected to said chemicahapplying operation and a section not sub- I jected to said chemical-applying operation are subjected variations of said programming means for the purpose of said-voluminizingaoperation, 7. The process of claim 6, wherein the relationship betweenthe independent physical-structure variation-sensing steps and the performance of said chemical-applying and :voluminizing operations satisfies the formula l f=yarn from chemical-applying point to voluminizing point,

V V =speed ofmove'ment of; programming means, and

V =speed of movement: of the yarn.

8. The process of claim 1, wherein said physical structure variations ofysaidprogramming means are such as to cause changes of said physical characteristics in yarn sections of non-uniform length.

9. The process of treating yarn'having a basis of organic acidester of cellulose, comprising the steps of subjecting such yarn traveling between alsupply station and a take-up station to a lsap'onification and to a jet bulking operation; movingprogramming means of intermittently different physical structure past a detection station, sensing the variations in said physical structure of said programmingmeans at said detection station, andcontrolling both saidsaponification and said jet bulking operation through the intermediary of said sensed physical structure variations of said programming means to eifect alternating and successive starts and interruptions of said saponification and said jet bulking operation, whereby the receptiveness 55' of said yarn to normal acetate dyes and the bulkiness of said yarn are changed intermittentently each to an extent and at intervals predetermined'by said physical structure variations of said programming means.

10. Apparatus for treating yarn having a basis of organic acid ester of cellulose, comprising saponifying means for subjecting said yarn intermittently to a saponification, jet bulking means for. intermittentlysubjecting said yarn to-a jet bulking operation, programming means of intermittently different physical'structure, means for sensing the physical structure variations of said programming, means, and means for alternatin'gly andsuccessively actuating and deactuating said saponifying means and said jet bulking means, in accordance with the sensed physical structure variations of said programming means, whereby the receptiveness of said'yarn to normal acetate dyes and the bulkiness of said yarn are intermittently changed; V a

11. Apparatus according to claim 10, said programming means comprising at least one pattern tape having intermittent portions of different light transmission characteris- 13 tics which portions constitute the intermittent physical structure to be sensed by said sensing means.

12. Apparatus according to claim 11, said portions of different light transmission characteristics being perforate and imperforate, said tape being adapted for movement past said sensing means, said sensing means comprising a feeler electrode located at one face of said tape and slidably engaging the same, and a base electrode located at the other face of said tape and adapted to be electrically contacted by said feeler electrode when one of said perforations of said pattern tape is disposed between said electrodes.

13. Apparatus according to claim '11, said pattern tape being adapted for movement past said sensing means, said sensing means comprising a photosensitive element located atone face of said pattern tape, and a light source located at the other face of said pattern tape, whereby light from said source actuates said photosensitive element Whenever one of the portions of said pattern tape having the greater light transmission characteristic is dis posed between said element and said source.

14. Apparatus according to claim 11, said tape being adapted for movement past said sensing means, said sensing means comprising a pair of pick-up units adapted LO sense said portions of said pattern tape of different light transmission characteristics at spaced points along the path of movement of said pattern tape, one of said pick-up units being operatively connected with said saponifying means, and other pick-up unit being operatively connected with said jet bulking means.

15. Apparatus according to claim 10, said programming means comprising a pair of pattern tapes each having intermittent portions of different light transmission characteristics which constitute the intermittent physical structure to be sensed by said sensing means, said sensing means comprising a pair of spaced pick-up units each adapted to sense said different portions of a respective one of said pattern tapes, said pattern tapes being adapted for movement past the associated pick-up units, and the arrangement of said saponifying means, said jet bulking means and said pick-up units being predetermined to satisfy the formula V =speed of movement of the pattern tape, and V =speed of movement of the yarn.

16. Apparatus according to claim 10, said programming means comprising at least one pattern cam provided on its actuating surface with a plurality of alternating elevations and depressions, said elevations and depressions of said pattern cam constituting the intermittent physical structure to be sensed by said sensing means.

17. Apparatus for treating yarn having a basis of organic acid ester of cellulose, comprising saponifying means for subjecting said yarn intermittently to a saponification, jet bulking means for intermittently subjecting said yarn to a jet bulking operation, programming means of intermittently different physical structure, means for sensing the physical structure variations of said programming means, and means for alternatingly and successively actuating and deactuating said saponifying means and said jet bulking means in accordance with the sensed physical structure variations of said programming means, whereby the receptiveness of said yarn to normal acetate dyes and the bulkiness of said yarn are intermittently changed, said saponifying means comprising a trough containing a liquid saponifying agent, a transfer roller rotatably mounted above said trough and having its lower portion immersed in said saponifying agent and its uppermost peripheral region located in the path of movement of said yarn a rocker shaft positioned adjacent said trough, and a transverse arm carried by said shaft and provided at one end with a yarn-engaging element extending across said path of movement of said yarn adjacent said transfer roller, said means for actuating and deactuating said saponifying means comprising a pneumatic motor operatively connected with said rocker shaft and adapted to tangularly move the same about its axis so as to raise and lower said yam-engaging element for inhibiting and permitting, respectively, contact between said yarn and said transfer roller, and valve means operatively connected with said pneumatic motor for controlling the flow of fluid thereinto, said sensing means being operatively connected to said valve means for actuating the same alternatingly in accordance with the sensed physical structure variations of said programming means.

.13. Apparatus according to claim 10, said jet bulking means comprising a high pressure fluid jet in which said yarn when passing therethrough is subjected to the action of a turbulently flowing bulking fluid, and clamping means located adjacent the yarn exit part of said jet and alongside the path of movement of said yarn out of said jet, said clamping means being adapted to be actuated and deactuated for permitting and inhibiting, respectively,

movement of said yarn away from said jet and past said clamping means.

19. Apparatus according to claim 18, said clamping means comprising a pair of substantially fiat-faced discs between which said yarn is adapted to pass, said discs when brought into face to face contact clamping said yarn therebetween.

20. The combination of a downtwister for transferring synthetic filament yarn having a basis of organic ester of cellulose from a supply spool to a take-up spool, with saponifying means for subjecting said yarn intermittently to a saponification, with voluminizing means for subjecting said yarn intermittently to a voluminizing operation, with programming means of intermittently different physical structure, with means for sensing the physical structure variations of said programming means, and with means for alternatingly and successively actuating and deactuating said saponifying means and said voluminizing means in accordance with the sensed physical structure variations of said programming means, whereby the receptiveness of said yarn to normal acetate dyes and the voluminosity of said yarn are intermittently changed, said downtwister comprising feed roll means for drawing said yarn from said supply spool and feeding the same to said take-up spool, and downtwisting ring means for guiding the winding of said yarn onto said take-up spool, said saponifying means being located between said supply spool. and said feed roll means, and said voluminizing means being located between said feed roll means and said downtwisting ring means, said saponifying means comprising a trough containing a liquid saponifying agent, a transfer roller rotatably mounted above said trough and having its lower portion immersed in said saponifying agent and its uppermost peripheral region located in the path of movement of said yarn from said supply spool to said feed roll means, a rocker shaft positioned adjacent said trough, and a transverse arm carried by said shaft and provided with a yarn-engaging element extending across said path of movement of said yarn adjacent said transfer roller, said voluminizing means comprising a high pressure fluid jet in which said yarn when passing therethrough is adapted to be subjected to the action of a turbulently flowing bulking fluid, and clamping means located intermediate said jet and said downtwisting ring means and adapted when actuated to inhibit movement of said yarn to said downtwisting ring means, said means for actuating and deactuating said saponifying means and said voluminizing means comprising first and second pneumatic motors operatively connected, respectively, with said rocker shaft and said clamping means, and first and second valve means operatively connected with said first and second pneumatic motors, respectively for controlling the flow of operating fluid thereinto, said,"

sensing means being operatively connected to said first and second valve means for actuating the same. in accordance with the sensed physical structure variations of said programming; means. 7

21'. The com'bination of a-downtwister for transferring synthetic filament yarn having a basis of organic ester of ingthe winding of saidiyarn onto said take-up spool, with t saponifying means forsubjecting saidyarn intermittently to'asaponification, said saponifyingmeans being located 7 between said supply'spool and said feed'roll means, with voluminizing means for subjecting said yarn intermittently to a voluminizing operatiomsaid yoluminizing means being located between said feed roll means and'said downtwisting ringmeans, with programmingjmeans of intermittently different physical structure, means for sensing thephysic-al structure variations ofsaid programming means, and means for alternatingly and successively actuating and deactuat-- ing saidsaponifying means and said voluminizing means in: accordance. with the sensed physical structure variasnegooo tions of said programming means, whereby. the receptiveness. of said yarn to, normal iacetate dyes and the t voluminosity of said yarn areintermittently changed.

'- References Cited by the Examiner UNITED STATES PATENTS:

1,966,440 7/34 'D'i'ckie et a'l. 57-1 57 X 2,064,279 12/ 36 Taylor et a1. 57-157 X 2,089,194 8/37 Dreyfus 57'157' X 2,669,001 2/54' Keen ,28'-1 2,783,609 3/57 Breen 57-1.40 2,807,864 10/57 Head 57-34 2,852,906 9/ 58 Breen 5 734 2,869,967 1/59 Breen 5 7 2,884,756 5/59 .Head 5734 2,931,090 4/6'0 Field 57'34 2,976,105- 3/61 Rose et' a1 19-238 X 1 3,017,737" 1/6 2 "Breen l 57.-34 3,047,932 8/62 7 Pittman et a1. 28-72 3,105,349 10/63 Palm et al .5734

FOREIGN PATENTS 776,410 67/57 Great Britain.

MERVIN' STEIN, Primary Ex amine r.

RUSSELL C. -MADER,, Examiner. 

20. THE COMBINATION OF A DOWNTWISTER FOR TRANSFERRING SYNTHETIC FILAMENT YARN HAVING A BASIS OF ORGANIC ESTER OF CELLULOSE FROM A SUPPLY SPOOL TO A TAKE-UP SPOOL, WITH SAPONIFYING MEANS FOR SUBJECTING SAID YARN INTERMITTENTLY TO A SAPONIFICATION, WITH VOLUMINIZING MEANS FOR SUBJECTING SAID YARN INTERMITTENTLY TO A VOLUMINIZING OPERATION, WITH PROGRAMMING MEANS OF INTERMITTENTLY DIFFERENT PHYSICAL STRUCTURE, WITH MEANS FOR SENSING THE PHYSICAL STRUCTURE VARIATIONS OF SAID PROGRAMMING MEANS, AND WITH MEANS FOR ALTERNATINGLYAND SUCCESSIVELY ACTUATING AND DEACTUATING SAID SAPONIFYING MEANS AND SAID VOLUMINIZING MEANS IN ACCORDANCE WITH THE SENSED PHYSICAL STRUCTURE VARIATIONS OF SAID PROGRAMMING MEANS, WHEREBY THE RECEPTIVENESS OF SAID YARN TO NORMAL ACETATE DYES AND THE VOLUMINOSITY OF SAID YARN ARE INTERMITTENTLY CHANGED, SAID DOWNTWISTER COMPRISING FEED ROLL MEANS FOR DRAWING SAID YARN FROM SAID SUPPLY SPOOL AND FEEDING THE SAME TO SAID TAKE-UP SPOOL, AND DOWNTWISTING RING MEANS FOR GUIDING THE WINDING OF SAID YARN ONTO SAID TAKE-UP SPOOL, SAID SAPONIFYING MEANS BEING LOCATED BETWEEN SAID SUPPLY SPOOL AND SAID FEED ROLL MEANS, AND SAID VOLUMINIZING MEANS BEING LOCATED BETWEEN SAID FEED ROLL MEANS AND SAID DOWNTWISTING RING MEANS, SAID SAPONIFYING MEANS COMPRISING A TROUGH CONTAINING A LIQUID SAPONIFYING AGENT, A TRANSFER ROLLER ROTATABLY MOUNTED ABOVE SAID TROUGH AND HAVING ITS LOWER PORTION IMMERSED IN SAID SAPONIFYING AGENT AND ITS UPPERMOST PERIPHERAL REGION LOCATED IN THE PATH OF MOVEMENT OF SAID YARN FROM SAID SUPPLY SPOOL TO SAID FEED ROLL MEANS, A ROCKER SHAFT POSITIONED ADJACENT SAID TROUGH, AND A TRANSVERSE ARM CARRIED BY SAID SHAFT AND PROVIDED WITH A YARN-ENGAGING ELEMENT EXTENDING ACROSS SAID PATH OF MOVEMENT OF SAID YARN ADJACENT SAID TRANSFER ROLLER, SAID VOLUMINIZING MEANS COMPRISING A HIGH PRESSURE FLUID JET IN WHICH SAID YARN WHEN PASSING THERETHROUGH IS ADAPTED TO BE SUBJECTED TO THE ACTION OF A TURBULENTLY FLOWING BULKING FLUID, AND CLAMPING MEANS LOCATED INTERMEDIATE SAID JET AND SAID DOWNTWISTING RING MEANS AND ADAPTED WHEN ACTUATED TO INHIBIT MOVEMENT OF SAID YARN TO SAID DOWNTWISTING RING MEANS, SAID MEANS FOR ACTUATING AND DEACTUATING SAID SAPONIFYING MEANS AND SAID VOLUMINIZING MEANS COMPRISING FIRST AND SECOND PNEUMATIC MOTORS OPERATIVELY CONNECTED, RESPECTIVELY, WITH SAID ROCKER SHAFT AND SAID CLAMPING MEANS, AND FIRST AND SECOND VALVE MEANS OPERATIVELY CONNECTED WITH SAID FIRST AND SECOND PNEUMATIC MOTORS, RESPECTIVELY FOR CONTROLLING THE FLOW OF OPERATING FLUID THEREINTO, SAID SENSING MEANS BEING OPERATIVELY CONNECTED TO SAID FIRST AND SECOND VALVE MEANS FOR ACTUATING THE SAME IN ACCORDANCE WITH THE SENSED PHYSICAL STRUCTURE VARIATIONS OF SAID PROGRAMMING MEANS. 